MATERIAL REQUIREMENT PLANNING

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Presentation transcript:

MATERIAL REQUIREMENT PLANNING MATERIAL REQUIREMENT PLANNING(MRP) IS A SOFTWARE BASED PRODUCTION PLANNING AND INVENTORY CONTROL SYSTEM USED TO MANAGE MANUFACTURING PROCESSES.IT IS A PRODUCTION TOOL OF MANAGEMENT.

OBJECTIVES ENSURE MATERIALS AND PRODUCTS ARE AVAILABLE FOR PRODUCTION AND DELIVERY TO CUSTOMERS MAINTAIN LOWEST POSSIBLE LEVEL OF INVENTORY PLAN MANUFACTURING ACTIVITIES DELIVERY SCHEDULES AND PRCHASING ACTIVITIES

BENEFITS REDUCED INVENTORY LEVELS IMPROVRD PRODUCTIVITY REDUCED LEAD TIME IMPROVED CUTOMER SERVICE INCREASED PRODUCTION

ELEMENTS OF MRP MASTER PRODUCTION SCHEDULE(MPS) BILL OF MATERIALS(BOM) QUANTITY ON HAND SALES ORDER QUANTITIES/DUE DATES SCRAP RATE PURCHASE ORDER QUANTITIES/DUE DATES SAFETY STOCK REQUIREMENT

Master ProductionSchedule(MPS):MPS is designed to meet the market demand (both the firm orders and forecasted demand) in future in the taken planning horizon. MPS mainly depicts the detailed delivery schedule of the end products. However, orders for replacement components can also be included in it to make it more comprehensive.

Bill of Materials (BOM): BOM represents the product structure. It encompasses information about all sub components needed, their quantity, and their sequence of buildup in the end product. Information about the work centers performing buildup operations is also included in it.

Just-In-Time Production Systems Just-in-time (JIT) production systems take a “demand pull” approach in which goods are only manufactured to satisfy customer orders.

Major Features of a JIT System 1. Organizing production in manufacturing cells 2. Hiring and retaining multi-skilled workers 3. Emphasizing total quality management 4. Reducing manufacturing lead time and setup time 5. Building strong supplier relationships

Major Features of a JIT System What information may management accountants use? Personal observation by production line workers and managers Financial performance measures, such as inventory turnover ratios Nonfinancial performance measures of time, inventory, and quality.

SEVEN WASTES WASTE OF OVER PRODUCTION TRANSPORTATION WASTE PROCESSING WASTE PRODUCT DEFECTS WAITING/IDLE TIME INVENTORY WASTE WASTE OF MOTION

KANBAN A SYSTEM OF CONTINUOS SUPPLY OF COMPONENTS,PARTS AND SUPPLIES, SUCH THAT WORKERS HAVE WHAT THEY NEED, WHERE THEY NEED IT, WHEN THEY NEED IT KAN---VISUAL BAN---CARD